Customer Satisfaction Program 09M04 - Cooling System Corrosion (09M04)

SUBJECT

Customer Satisfaction Program 09M04 - Supplement #1: 

Certain 2007 through 2009 Model Year Edge and MKX Vehicles

Cooling System Corrosion

REF

Customer Satisfaction Program 09M04  - Dated November 10, 2009

Certain 2007 through 2009 Model Year Edge and MKX Vehicles

Cooling System Corrosion

REASON FOR THIS SUPPLEMENT

This bulletin is being re-issued to include enhanced technical information. A Critical Points Sheet (Attachment IV).

PROGRAM TERMS

This program provides a heater performance evaluation, and if necessary, a cooling system flush. It also extends the coverage of the heater core to 6 years or 105,000 miles from the warranty start date of the vehicle, whichever occurs first. If a vehicle has already exceeded the mileage limit, this coverage will last through May 31, 2010. Coverage is automatically transferred to subsequent owners.

VEHICLES COVERED BY THIS PROGRAM

Certain 2007 through 2009 Edge and MKX vehicles built from Job #1 2007 through January 19, 2009. Affected vehicles are identified in OASIS.

REASON FOR PROVIDING ADDITIONAL COVERAGE

In some of the affected vehicles, cooling system corrosion may lead to contamination of the heater core. This contamination may, over time, lead to reduced heater performance.

SERVICE ACTION

If an owner of an affected vehicle experiences reduced heater performance, dealers are to evaluate the performance of the heater and if necessary, flush the cooling system. The flush will be performed using a new Rotunda Special Service Tool Kit #303-1525 and new Motorcraft Engine Cooling System Cleaner (VC-11) to remove contamination. The vehicle will then be refilled with a different coolant, Motorcraft Specialty Green Engine Coolant with Bittering Agent (VC-10-A2). This service must be performed on affected vehicles at no charge to the vehicle owner.

ROTUNDA SPECIAL SERVICE TOOL KIT

A new Rotunda Special Service Tool Kit #303-1525 specifically developed for this repair will be shipped to dealers, prioritized by sales volume and colder climate, starting in November and ending late December 2009. This new tool kit is provided at no cost. The tool kit will arrive in a box with the tool kit part number on a white label, "Attention Service Manager" on an orange label, and "For Use With FSA 09M04" on a yellow label. For tool kit information, contact Rotunda (1-800-ROTUNDA/1800-768-8632) option #5.

OWNER NOTIFICATION MAILING SCHEDULE

Mailing will begin by the week of December 7th, 2009.

ATTACHMENTS

1. Attachment I: Administrative Information
2. Attachment II: Labor Allowances and Parts Ordering Information
3. Attachment III: Technical Information
4. Attachment IV: Critical Points Sheet
5. Customer Notification Letter
6. Customer Information Sheet

QUESTIONS & ASSISTANCE

1. Special Service Support Center (dealer only) ... 1-800-325-5621
2. Rotunda (special service tool kit questions; option #5 - dealer only) ... 1-800-768-8632

OASIS ACTIVATED?

Yes, OASIS will be activated on November 10, 2009.

FSA VIN LIST ACTIVATED?

No.

STOCK VEHICLES

Do not perform this program unless the affected vehicle exhibits the covered condition.

SOLD VEHICLES

Only owners with affected vehicles that exhibit the covered condition will be directed to dealers for repairs.

TITLE BRANDED / SALVAGED VEHICLES

Affected title branded and salvaged vehicles are eligible for this Field Service Action.

RELATED DAMAGE

If a related damage condition exists that you believe to be caused by the covered condition, call the Special Service Support Center to request approval prior to the repair of any related damage. Requests for approval after completion of the repair will not be granted.

ADDITIONAL LABOR TIME

• If a condition exists that requires additional labor to complete the repair, call the Special Service Support Center to request approval prior to performing any additional labor. Requests for approval after completion of the repair will not be granted.
• If you encounter aftermarket equipment or modifications to the vehicle which might prevent the repair of the covered condition, call the Special Service Support Center.

OWNER REFUNDS

• Ford Motor Company will only refund owner-paid repairs covered by this program if the repair was performed prior to the date of the Customer Notification Letter (or after the date of the letter if an emergency repair was made away from the servicing dealer). Non-covered repairs, or those judged by Ford to be excessive, will not be reimbursed.
• Refunds will only be provided for the cost associated with the diagnosis and replacement of the heater core and/or cooling system flush related to reduced heater performance.
• Vehicles that have had a heater core replacement or cooling system flush and are experiencing reduced heater performance will need to have this service performed, beginning with the heater performance evaluation.
• Multiple refunds should be submitted on one repair line and the invoice details for each repair should be detailed in the comments section of the claim. If a repair is performed on the same visit, the repair and refunds should be submitted on separate repair lines.
• The refund period for repairs performed prior to the date of the Customer Notification Letter will expire on May 31, 2010.
• Refund Claiming Information (submit on separate repair line).
  1. - Program Code: 09M04
  2. - Misc. Expense: ADMIN - 0.2 Hrs.
  3. - Misc. Expense: REFUND

RENTAL VEHICLES

The use of rental vehicles is not authorized for this program.

CLAIMS PREPARATION AND SUBMISSION

• Enter claims using Direct Warranty Entry (DWE).
• Refund or related damage must be claimed on a repair line that is separate from the repair line on which the FSA is claimed. Related damage requires prior approval from the Special Service Support Center.
• "MT" labor should be submitted on a separate repair line with the related damage flag checked. "MT" labor requires prior approval from the Special Service Support Center.
• Refer to ACESII manual for claims preparation and submission information.
• Claiming information for 5 gallons of distilled water up to $1.25 per gallon (submit as Misc. Expense code "OTHER" on the same repair line as the repair).
  • Program Code: 09M04
  • Misc. Expense: OTHER for actual cost, not to exceed $6.25 maximum

LABOR ALLOWANCES

PARTS REQUIREMENTS / ORDERING INFORMATION

Order your parts requirements through normal order processing channels.

The DOR/COR number for this program is 50410.

Questions regarding parts should be directed to the Special Service Support Center (1-800-325-5621) or E-mailed to: Ford@Renkim.com.

DEALER PRICE

For latest prices, refer to DOES II.

PARTS RETENTION AND RETURN

Affected water pump inlet tubes and heater cores are subject to random selection for return to the Ford Warranty Parts Analysis Center (WPAC). Refer to your daily PEARS (Parts Entry and Return System) register for part disposition and return instructions.

Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return Procedures."

OVERVIEW

In some of the affected vehicles, cooling system corrosion may lead to contamination of the heater core. This contamination may, over time, lead to reduced heater performance.

This service procedure is very extensive and detailed. Listed below are the sections of the service procedure along with highlights of important information.

VERIFICATION 

• Measure temperature difference in the center vents
• If greater than 15° F (8° C), proceed to the service procedure
• If less than 15° F (8° C), follow normal WSM diagnosis

EQUIPMENT LIST 

• Rotunda Tool Kit #303-1525
• Additional equipment needed

WATER PUMP INLET TUBE 

• Replace the water pump inlet tube if the engine build date is on or before 4/1/2008
• Do NOT replace the water pump inlet tube, if the engine build date is on or after 4/2/2008

PRE-RINSE 

• Removes old coolant from the cooling system
• Coolant MUST NOT mix with the VC-11 flush chemical

VC-11 FLUSH 

• Removes contamination from the cooling system
• VC-11 flush chemical temperature has to be between 135° F (57° C) and 150° F (65° C) for optimum cleaning performance

POST-RINSE AND FILL 

• Removes VC-11 from the cooling system
• VC-11 flush chemical MUST NOT mix with the new coolant
• Necessary to use 5 gallons of distilled water for the final system fill

VERIFICATION

VERIFY THE CUSTOMER CONCERN BY PERFORMING THE FOLLOWING HEATER PERFORMANCE EVALUATION.

1. Idle the engine at shop ambient temperature of 60° F (15° C) or higher, until the engine is fully warmed up.
2. Set the front climate temperature control to the hottest setting.
3. Set the mode to panel/vent (with all vents OPEN) and make sure the A/C is switched to the OFF position. Do NOT set the temperature control to the recirculation mode.
4. Set the blower to the highest speed.
5. Idle the engine for 5 minutes with the hood closed.
6. Measure the difference in the discharge air temperature between the left-center vent and the right-center vent as shown in Fig 1. The difference should be less than 15° F (8° C) to meet the performance requirement.

If the temperature DIFFERENCE IS LESS than 15° F (8° C), continue with normal Workshop Manual (WSM) diagnostic procedures. Do NOT proceed with this Service Procedure.

If the temperature DIFFERENCE IS MORE than 15° F (8° C), continue to the Service Procedure.

Fig 1: Measuring Difference In Discharge Air Temperature Between Vents

SERVICE PROCEDURE

NOTICE:  ALL STEPS OF THIS SERVICE PROCEDURE MUST BE COMPLETED IN ORDER TO PROPERLY CLEAN THE COOLING SYSTEM. FAILURE TO FOLLOW THESE STEPS WILL COMPROMISE COOLANT PROTECTION CAPABILITY.

EQUIPMENT LIST 

Necessary equipment for the cooling system flush:

1. Rotunda Tool Kit #303-1525
2. Two large radiator hose pinch-off pliers (not supplied with the tool kit)
3. One clean 5 gallon bucket (not supplied with the tool kit)
4. An infrared thermometer or equivalent (not supplied with the tool kit)
5. Safety equipment (eye protection and chemical gloves, not supplied with the tool kit)
6. AirLift Cooling Tester UVU-550000 (not shown, formerly Radkit Plus)
7. Shop water supply hose (not shown)
8. Radiator drain pan (not shown)

Fig 2: Necessary Equipment For Cooling System Flush

WATER PUMP INLET TUBE 

1. Place a drain pan under the radiator drain valve and completely drain the cooling system through the radiator drain (degas bottle cap should be loose for proper draining).
2. Remove the air cleaner as an assembly.
   • Disconnect the mass air flow (MAF) sensor electrical connector.
   • Loosen the clamp and disconnect the air cleaner assembly outlet pipe from the air cleaner assembly.
   • Remove the air cleaner assembly bolts.
   • Separate the 2 air cleaner assembly feet from the rubber grommets.
3. NOTE:  The engine build date is on the engine code label, located on the RH cam cover or the front cover. The date is positioned in the center of the label in a date/month/year sequence.

   Locate and check the engine build date. See Fig 3.

   Fig 3: Engine Code Label Location

   

   If the engine build date is ON or AFTER 4/2/2008, the water pump inlet tube does NOT need to be replaced. Proceed to Step 11.

   If the engine build date is ON or BEFORE 4/1/2008, it will be necessary to replace the water pump inlet tube. Proceed to Step 4.

4. Remove the coolant hoses from the thermostat housing. See Fig 4.
   Fig 4: Coolant Hoses Removed From Thermostat Housing

   
5. Remove the 3 thermostat housing bolts.
6. Separate the thermostat housing from the water pump inlet tube.
7. NOTE:  The water pump inlet tube orientation can be determined by the length of the radius at the ends of the tube. The longer radius end is inserted into the water pump housing. See Fig 5.

   Remove the water pump inlet tube from the water pump housing using a slight twisting motion. The inlet tube must be replaced with a new inlet tube without paint on the interior surface of the tube.

   Fig 5: Water Pump Inlet Tube Orientation

   
8. Lubricate the new water pump inlet tube O-ring with clean engine coolant.
9. Install the new water pump inlet tube into the water pump housing.
10. Install the thermostat housing.
    • Lubricate the thermostat housing O-ring with clean engine coolant.
    • Install the thermostat housing and 3 housing bolts. Tighten the bolts to 10 Nm (89 lb-in).
    • Install the coolant hoses to the thermostat housing EXCEPT for the heater core inlet and outlet hoses. See Fig 4.

PRE-RINSE 

NOTE:  The pinch-off pliers are used to control the direction of fluids in certain areas of the cooling system. They are also used for optimum cleaning and to prevent air from entering into the cooling system.

11. If the water pump inlet tube was NOT replaced, disconnect both the heater core inlet and outlet hoses from the thermostat housing. See Fig 6.
    Fig 6: Heater Core Inlet And Outlet Hoses On Thermostat Housing

    
12. Remove the 2 thermostat housing cover bolts and remove the thermostat.
13. NOTE:  Make sure that the upper radiator hose is correctly positioned into the locating bracket on the cooling fan shroud. If the upper radiator hose is above or below the locating bracket, air can be trapped in the hose and overheating will occur. See Fig 7.

    Position the flush tool kit plug into the thermostat housing to control the flow and install the O-ring, thermostat housing cover, and bolts. Tighten to 10 Nm (89 lb-in). See Fig 8.

    Fig 7: Upper Radiator Hose Positioned In Locating Bracket On Cooling Fan Shroud

    
    Fig 8: Positioning Flush Tool Kit Plug Into Thermostat Housing

    
14. NOTICE:  The routing of the heater core inlet and outlet hoses, as well as the flush tool kit drain and pump hoses is critical to the flushing procedure. Incorrect routing will inhibit the Motorcraft® Engine Cooling System Cleaner VC-11/water mixture from circulating and may cause an overheating condition. See Fig 9 for the cooling system flush hose routing.

    With the heater core inlet and outlet hoses off from step 11:

    • Connect the heater core inlet hose (IB - lower hose) to the heater return port (upper port) on the thermostat housing.
    • Connect the flush tool kit drain hose to the heater core inlet port on the thermostat housing.
    • Connect the flush tool kit hose-to-pump to the heater core outlet hose (OB) for the reverse flushing.
    Fig 9: Hose Routing For Engine Cooling System Flush

    
15. Route the flush tool kit drain and fill hoses under the thermostat housing and out of the engine compartment. Make sure that the hoses are NOT kinked.
16. NOTICE:  To prevent any damage to the flush tool kit drain and fill hoses, place shop towels between the radiator shroud and the hoses.

    Position several shop towels between the hoses and the radiator shroud. See Fig 10.

    Fig 10: Flush Tool Kit Drain And Fill Hoses Routing Out Of Engine Compartment

    
17. Place the flush tool kit pump onto a tool cart in front of the vehicle. Connect the fill hose from the heater core outlet to the pump. See Fig 11.
    Fig 11: Flush Tool Kit Connected To Vehicle

    
18. Position the flush tool kit 5 gallon bucket onto the tool cart along side the pump. See Fig 11.
19. Reinstall the air cleaner assembly and connect the MAF electrical connector. It is NOT necessary to secure the air cleaner assembly at this time.
20. NOTE:  For measuring purposes, it is recommended to use a clean 5 gallon shop bucket.

    Place a separate empty 5 gallon shop bucket on the floor in front of the vehicle. See Fig 11.

21. Place the flush tool kit drain hose from the heater core inlet port on the thermostat housing into the empty bucket on the floor. See Fig 11.
22. Install the tool kit water valve onto the shop fresh water supply hose. Completely fill the cooling system through the degas bottle with fresh water until the water flows from the radiator drain.
23. Allow the radiator to completely drain. Close the radiator drain and install the degas bottle cap.
24. NOTE:  The pinch-off pliers are used to control the direction of fluids in certain areas of the cooling system. They are also used for optimum cleaning and to prevent air from entering into the cooling system.

    NOTE:  If the vehicle is being lifted to install and remove the lower radiator hose pinch-off pliers, the flush tool kit pump must be secured onto the radiator shroud while lifting.

    Position and clamp the pinch-off pliers onto the upper radiator hose (see Fig 12) and the lower radiator hose (see Fig 13) as close to the radiator as possible.

    Fig 12: Pinch-Off Pliers On Upper Radiator Hose

    
    Fig 13: Pinch-Off Pliers On Lower Radiator Hose

    
25. Place the flush tool kit suction hose from the pump into one of the small holes in the lid of the flush tool kit bucket that is along side of the pump. The hose MUST be kept a minimum of 2 inches from the bottom of the tool kit bucket.
26. Using the shop fresh water supply, fill the flush tool kit bucket with fresh water. Use the tool kit valve attached to the shop fresh water supply hose to maintain the water level in the tool kit bucket.
27. Connect a shop air supply to the pump, with the fresh water supply on, and maintain the water level in the tool kit bucket.
28. NOTE:  Do NOT allow the tool kit supply bucket to become low or empty. This will introduce air into the cooling system and cause an overheating condition.

    With the fresh water supply on, monitor and maintain the water level in the tool kit bucket.

29. NOTE:  Dispose of old coolant and flushing water contaminated with antifreeze in accordance with local, state and federal laws.

    Allow a minimum of 10 gallons of water to flush through the engine and out the drain hose into the shop bucket on the floor. It will be necessary to disconnect the shop air supply from the pump to eliminate the water flow from the drain hose while emptying the shop bucket.

30. After a minimum of 10 gallons of water has flushed through the engine, disconnect the shop air from the pump and turn off the fresh water supply.
31. Remove the tool kit bucket lid and empty the bucket.

VC-11 FLUSH 

32. NOTE:  Both the suction and drain hoses MUST be kept a minimum of 2 inches from the bottom of the tool kit bucket. This will prevent any air from entering into the cooling system and causing an overheating condition.

    Reposition the drain hose from the 5 gallon bucket on the floor into one of the small holes in the lid of the flush tool kit bucket on the tool cart. See Fig 14.

    Fig 14: Drain Hose Positioned Into Flush Tool Kit Bucket On Tool Cart

    
33. Remove the pinch-off pliers from upper and lower radiator hoses.
34. Install the pinch-off pliers onto the flush tool kit drain and suction hose closest to the flush tool kit bucket lid. See Fig 15.
    Fig 15: Pinch-Off Pliers On Flush Tool Kit Drain And Suction Hoses

    
35. WARNING:  THE USE OF SAFETY EQUIPMENT SUCH AS EYE PROTECTION AND CHEMICAL GLOVES IS REQUIRED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN SERIOUS PERSONAL INJURY.

    NOTICE:  Bring the Motorcraft® Engine Cooling System Cleaner VC-11 to room temperature of 68° F (20° C) and shake well. Follow all of the Motorcraft® Engine Cooling System Cleaner VC-11 instructions and Precautions.

    Add 2 gallons of Motorcraft® Engine Cooling System Cleaner VC-11 to the flush tool kit bucket that is on the tool cart. Do not dilute the Motorcraft® Engine Cooling System Cleaner VC-11 in the flush tool kit bucket.

36. NOTICE:  It is necessary to use the AirLift Cooling Tester UVU-550000 (formerly Radkit Plus) to remove any air from the cooling system. If air remains in the cooling system, the air will inhibit the circulation of the Motorcraft® Engine Cooling System Cleaner VC-11/water mixture and will cause an overheating condition and possible damage to the engine.

    Rinse the shop bucket and fill with fresh water. Place the shop bucket so that the fill hose from the AirLift Cooling Tester UVU-550000 (formerly Radkit Plus) will siphon the fresh water out of the bucket. Install the AirLift Cooling Tester UVU-550000 onto the degas bottle. Prime the AirLift Cooling Tester to remove any air from the tester (priming instructions are in the tester's literature). Fill the cooling system.

37. Remove the AirLift Cooling Tester UVU-550000 from the degas bottle and install the degas bottle cap. Make sure that the degas bottle is filled to 1 inch (25 mm) above the COLD FILL LEVEL.
38. Remove the pinch-off pliers from both hoses at the flush tool kit bucket.
39. Position one of the pinch-off pliers onto the upper radiator hose closest to the radiator.
40. Connect shop air supply to the tool kit pump. The pump will start to siphon the Motorcraft® Engine Cooling System Cleaner VC-11 from the bucket into the engine.
41. NOTICE:  The Motorcraft® Engine Cooling System Cleaner VC-11/water mixture temperature MUST be between 135° F (57° C) AND 150° F (65° C).

    The temperature MUST exceed 135° F (57° C) for the required cleaning efficiency, and MUST NOT exceed 150° F (65° C) or damage to the engine may occur.

    If the engine or the Motorcraft® Engine Cooling System Cleaner VC-11/water mixture temperature EXCEEDS 150° F (65° C), the heater blower motor may be turned on to help cool down the engine cooling system. If the Motorcraft® Engine Cooling System Cleaner VC-11/water mixture STILL EXCEEDS 150° F (65° C), the engine MUST be turned off and the key in the ON position to allow the heater blower motor to continue to operate. Allow the engine to cool down with the flush tool kit pump still circulating the Motorcraft® Engine Cooling System Cleaner VC-11/water mixture.

With the heater in the OFF position, start the engine and idle until the Motorcraft® Engine Cooling System Cleaner VC-11/water mixture temperature reaches 140° F (60° C). Monitor the Motorcraft® Engine Cooling System Cleaner VC-11/water mixture temperature using an infrared thermometer or equivalent in the flush tool kit bucket.

42. When the Motorcraft® Engine Cooling System Cleaner VC-11/water mixture temperature reaches 140° F (60° C), remove the pinch-off pliers from the upper radiator hose.
43. Disconnect the A/C high pressure cut-off switch electrical connector. This will activate the engine cooling fans. It may take a few seconds until the cooling fans come on. See Fig 16.
    Fig 16: A/C High Pressure Cut-Off Switch Electrical Connector Location

    
44. THE NOTICES AND NOTES IN THIS STEP CONTAIN PERTINENT INFORMATION THAT MUST BE FOLLOWED AND ARE ESSENTIAL FOR THE CLEANING PROCESS. FAILURE TO FOLLOW THESE INSTRUCTIONS WILL INHIBIT THE CLEANING PROCESS AND MAY CAUSE DAMAGE TO THE ENGINE.

    NOTICE:  Make sure that the radiator is NOT obstructed for maximum air flow. Any deflection of air may cause an overheating condition.

    NOTICE:  The Motorcraft® Engine Cooling System Cleaner VC-11/water mixture temperature MUST NOT EXCEED 150° F (65° C) or damage to the engine may occur. If the Motorcraft® Engine Cooling System Cleaner VC-11/water mixture temperature EXCEEDS 150° F (65° C), the heater blower motor can be turned ON to reduce the mixtures temperature. If the Motorcraft® Engine Cooling System Cleaner VC-11/water mixture temperature STILL EXCEEDS 150° F (65° C), the engine MUST be turned OFF and the key left ON. The key MUST remain on for the operation of the heater blower motor to allow the engine to cool down.

    Continue the flush using the flush tool kit pump, circulating the Motorcraft® Engine Cooling System Cleaner VC-11/water mixture through the cooling system.

    NOTICE:  Do NOT allow the degas bottle to run low or empty. This will allow air to enter the cooling system and will cause an overheating condition and prevent the Motorcraft® Engine Cooling System Cleaner VC-11/water mixture from circulating through the entire engine and cooling system.

    NOTE:  The engine MUST idle for a MINIMUM of 2 hours with the Motorcraft® Engine Cooling System Cleaner VC-11/water mixture circulating at a temperature between 135° F (57° C) and 150° F (65° C) to achieve required cleaning efficiency.

    Step 44 continued:

    NOTE:  If the ambient temperature is 75° F (24° C) or less, it may be necessary to perform one of the following steps to maintain the Motorcraft® Engine Cooling System Cleaner VC-11/water mixture temperature above 135° F (57° C):

    • On vehicles equipped with a trailer tow package, it may be necessary to disconnect one of the vehicle's cooling fans to decrease air flow through the radiator. See Fig 17.
    • On vehicles NOT equipped with trailer tow package, reconnect the A/C high pressure cut-off switch electrical connector. This will shut the fans off. See Fig 16.

    Allow the engine to idle for a MINIMUM of 2 hours. The Motorcraft® Engine Cooling System Cleaner VC-11/water mixture temperature MUST remain between 135° F (57° C) to 150° F (65° C).

    Fig 17: Cooling Fan Electrical Connectors

    

    Step 44 continued:

    NOTE:   To control any odor from the Motorcraft® Engine Cooling System Cleaner VC-11/water mixture during the flush, install a shop exhaust hose into the lid of the tool kit bucket.

    To control any odor from the Motorcraft® Engine Cooling System Cleaner VC-11/water mixture, it is recommended to install a shop exhaust hose into the lid of the tool kit bucket. See Fig 18.

    Fig 18: Shop Exhaust Hose In Lid Of Tool Kit Bucket

    
45. EVERY half hour monitor the degas bottle for the correct level and measure the temperature in the tool kit bucket. DO NOT allow the Motorcraft® Engine Cooling System Cleaner VC-11/water mixture to get below the COLD FILL LEVEL. If necessary, release cooling system pressure by loosening the degas bottle cap slowly allowing air to escape and the degas bottle to fill to 1 inch (25 mm) above the COLD FILL LEVEL.
46. After the engine has idled for a MINIMUM of 2 hours, turn the engine OFF and leave the key in the ON position. Turn the heater blower motor ON and select the highest blower speed.
47. Continue flushing until the cooling system cleaner/water mixture reaches 120° F (49° C) with the heater blower motor on high. The temperature can be identified using an infrared thermometer or equivalent to monitor the mixture temperature in the flush tool kit bucket.
48. Disconnect shop air from the flush tool kit pump.
49. Turn the ignition key OFF.
50. Connect the A/C High Pressure switch and the cooling fan motor electrical connector (if disconnected).

POST-RINSE AND FILL 

WARNING:  THE USE OF SAFETY EQUIPMENT SUCH AS EYE PROTECTION AND CHEMICAL GLOVES IS REQUIRED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN SERIOUS PERSONAL INJURY.

51. NOTE:  Dispose of Motorcraft® Engine Cooling System Cleaner VC-11/water mixture in the same way as coolant in accordance with local, state and federal laws.

    Empty and rinse the flush tool kit bucket, and then fill with fresh water.

52. Using caution, slowly open and remove the degas bottle cap.
53. Using caution, open the radiator drain.
54. NOTE:  Dispose of Motorcraft® Engine Cooling System Cleaner VC-11/water mixture in the same way as coolant in accordance with local, state and federal laws.

    Allow the radiator to drain completely (degas bottle cap should be OFF).

55. Fill the degas bottle completely with fresh water and allow the radiator to drain.
56. Close the radiator drain and install the degas bottle cap.
57. Place an empty 5 gallon bucket on the floor in front of the vehicle.
58. Remove the flush tool kit drain hose from the flush tool kit bucket and place the drain hose into the empty shop bucket.
59. Install pinch-off pliers on the upper and lower radiator hoses as close to the radiator outlets as possible. See Fig 12) and Fig 13 .
60. NOTICE:  Do NOT allow the flush tool kit bucket to run low or empty during the post-rinse and fill procedure. This will allow air to enter into the cooling system and cause an overheating condition.

    Keep the fresh water hose in the tool kit bucket and monitor the water level. Do not allow the bucket to run low or empty.

61. Connect air supply to the pump.
62. Allow a minimum of 10 gallons of water to flush through the engine and out the drain hose into the shop bucket on the floor. It will be necessary to disconnect the shop air supply from the pump to eliminate the water flow from the drain hose while emptying the shop bucket.
63. NOTE:  Remove ONLY the pinch-off pliers from the lower radiator hose in this step.

    Remove the pinch-off pliers from the lower radiator hose.

64. NOTICE:  Distilled water must be used for the final 5 gallon flush and fill.

    After flushing the system with a minimum of 10 gallons of fresh shop water, continue the flush using an additional 5 gallons of distilled water.

65. Remove the pinch-off pliers from the upper radiator hose.
66. Remove air supply from flush tool kit pump.
67. Disconnect the flush tool kit suction hose from the pump and remove the drain hose from the shop bucket. Move the tool cart with the bucket and pump aside.
68. Remove the degas bottle cap.
69. NOTE:  Dispose of Motorcraft® Engine Cooling System Cleaner VC-11/water mixture in the same way as coolant in accordance with local, state and federal laws.

    Open the radiator drain and completely drain the radiator.

70. Close the radiator drain.
71. Remove the Air Cleaner Assembly.
72. NOTE:  A black residue may be evident after the flushing procedure. This is a normal condition and requires NO action.

    Remove the heater core inlet hose from the heater return port on the thermostat housing.

73. Remove the drain hose from the heater core inlet port on the thermostat housing.
74. Remove the thermostat housing cover and remove the flush tool kit plug.
75. Install the thermostat and housing cover. Tighten the bolts to 10 Nm (89 lb-in).
76. Install the heater core inlet and outlet hoses onto the thermostat housing. See Fig 19.
    Fig 19: Heater Core Inlet And Outlet Hoses On Thermostat Housing

    
77. Install the Air Cleaner Assembly.
    • Install the air cleaner assembly into the rubber grommets.
    • Install the air cleaner assembly bolt and tighten to 9 Nm (80 lb-in).
    • Connect the air cleaner assembly outlet pipe and tighten the clamp to 5 Nm (44 lb-in).
    • Connect the MAF sensor electrical connector.
78. NOTICE:  The engine at this stage is filled with distilled water. The engine holds approximately 50% of the cooling system capacity. Add concentrated coolant, MOTORCRAFT® SPECIALTY GREEN ENGINE COOLANT, VC-10-A2 (US) or CVC-10-A (CANADA). Do NOT use the pre-diluted GENUINE MAZDA® EXTENDED LIFE COOLANT. Failure to follow these instructions may result in engine damage or cooling system concerns.

    Using the AirLift Cooling Tester UVU-550000 (formerly Radkit Plus), add 5.8 qts (5.5 L) for base models and 6.3 qts (6.0 L) for trailer tow models (vehicles equipped with an oil cooler) of 100% pure concentrated coolant. Use concentrated coolant, Motorcraft® Specialty Green Engine Coolant VC-10-A2 (US) or CVC-10-A (Canada) to the cooling system. Continue with the purge of air from the system until the coolant reaches 1 inch (25 mm) above the COLD FILL LEVEL.

    The recommended coolant concentration is 50/50 or -34° F (-36° C) using Motorcraft® Specialty Green Engine Coolant VC-10-A2 (US) or CVC-10-A (Canada) to distilled water, as measured with a hydrometer or equivalent.

    • Maximum coolant concentration is 60/40, -60° F (-51° C) for cold weather areas.
    • Minimum coolant concentration is 40/60, -20° F (-29° C) for warm weather areas.

79. Turn the heater to OFF.

    WARNING:  ALWAYS ALLOW THE ENGINE TO COOL BEFORE OPENING THE COOLING SYSTEM. DO NOT UNSCREW THE COOLANT PRESSURE RELIEF CAP WHEN THE ENGINE IS OPERATING OR THE COOLING SYSTEM IS HOT. THE COOLING SYSTEM MAY BE UNDER PRESSURE; STEAM AND HOT LIQUID CAN COME OUT FORCEFULLY WHEN THE CAP IS LOOSENED SLIGHTLY. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN SERIOUS PERSONAL INJURY.

80. Start the engine and increase the engine speed to 3,500 rpm and hold for 30 seconds.
81. Turn the engine OFF and wait for 1 minute to purge any large air pockets from the cooling system.
82. NOTE:  Add concentrated coolant, Motorcraft® Specialty Green Engine Coolant VC-10-A2 (US) or CVC-10-A (Canada) to 1 inch (25 mm) above the top of the COLD FILL LEVEL of the degas bottle.

    Check the engine coolant level in the degas bottle and if necessary, fill to 1 inch (25 mm) above the top of the COLD FILL LEVEL when warm or to the top of the COLD FILL LEVEL when cold using concentrated coolant, Motorcraft® Specialty Green Engine Coolant VC-10-A2 (US) OR CVC-10-A (Canada).

83. Start the engine and let idle until the engine reaches normal operating temperature and the thermostat is fully open. A fully open thermostat can be verified by the radiator cooling fan cycling on at least once.
84. With the engine ON, thermostat open and the cooling fans cycled at least once, increase the engine speed to 3,500 rpm and hold for 30 seconds. Then allow the engine to idle for 30 seconds.
85. Turn the engine OFF and wait for 1 minute.
86. Repeat Steps 84 and 85 a total of 5 TIMES to remove any remaining air trapped in the system.
87. NOTE:  Add concentrated coolant, Motorcraft® Specialty Green Engine Coolant VC-10-A2 (US) or CVC-10-A (Canada) to 1 inch (25 mm) above the top of the COLD FILL RANGE of the degas bottle.

    Check the engine coolant level in the degas bottle, and if necessary, fill to 1 inch (25 mm) above the top of the COLD FILL LEVEL with the engine warm or to the top of the COLD FILL LEVEL with the engine cold using concentrated coolant, Motorcraft® Specialty Green Engine Coolant VC-10-A2 (US) or CVC-10-A (Canada).

88. Make sure the degas bottle cap is installed to at least one audible "click."
89. Overlay the new cooling system label onto the degas bottle cap that has been provided by service management.
90. Using the IDS, clear any codes that may have been set during the flush procedure.
91. Service management will provide the Customer Information Sheet to the customer for insertion into vehicle's Owner Guide. This Customer Information Sheet will remind the customer that a revised type of coolant has been installed in their vehicle and will need to be used from this point forward.

OVERVIEW

Here are a few critical points that have been developed to further highlight some areas of the procedure that are important for successful cooling system flushing.

CRITICAL POINTS

Not all steps of the inspection and service procedure will be covered in this document. It is extremely important, however, to perform all of the steps in order as outlined in Attachment III.

• The cause of this concern is cooling system corrosion that may lead to contamination of the heater core. Heater core replacement will NOT fix this concern because there will still be contamination left in the cooling system.
• Incorrect routing of the heater core inlet and outlet hoses, as well as the flush tool kit drain and pump hoses, can lead to low or high Motorcraft® Engine Cooling System Cleaner VC-11/water mixture temperature in the tool kit bucket. See Fig 9 of Attachment III for correct routing.
• It is critical to get ALL of the air out of the cooling system for the VC-11 flush and the post rinse and fill segments. If there is any air in the cooling system, it will inhibit the circulation and the cleaning capabilities of the VC-11/water mixture. Also, it will cause an overheating condition during the VC-11 flush segment.
• Air may enter into the cooling system if the AirLift Cooling Tester UVU-550000 (formerly Radkit Plus) is not "primed" per the instructions. Failure to follow priming instructions will allow the air in the tester's hose to enter the system.
• Air may also leak into the cooling system while using the AirLift Cooling Tester UVU-550000 (formerly Radkit Plus). It is important to check for leaks by creating and holding 24 - 26 in. Hg. vacuum on the cooling system. Vacuum that does not hold for 20 seconds indicates air leaking into the cooling system.
• Some of the other possible sources of air leaking into the cooling system are as follows:
  1. - Water pump inlet tube O-ring(s) damaged and/or not present.
  2. - Thermostat O-ring damaged and/or not present throughout the procedure.
  3. - Pinch-off pliers not correctly secured on the tool kit hoses.
• Air may be trapped in the cooling system and may not escape if:
  1. The upper radiator hose is not properly positioned into the upper radiator hose locating bracket on the cooling fan shroud.
  2. The vent hose check valve is plugged or installed backwards. This vent hose runs from the thermostat housing to the degas bottle (see Fig 4 of Attachment III)
• When preforming the VC-11 flush, the VC-11/water mixture temperature in the tool kit bucket MUST be kept between 135-150°F (57-65°C) for the required cleaning efficiency. The Motorcraft® Engine Cooling System Cleaner VC-11/water mixture MUST NOT exceed 150°F (65°C), or damage to the engine may occur.
• If the Motorcraft® Engine Cooling System Cleaner VC-11/water mixture temperature in the tool kit bucket cannot be maintained at or above 135°F (57°C):
  1. - Verify hose routing (refer to Fig 9 of Attachment III and check hose routing).
  2. - On vehicles equipped with trailer tow package, disconnect one of the vehicle's cooling fans.
  3. - On vehicles NOT equipped with trailer tow package, reconnect the A/C high pressure cut-off switch electrical connector. This will shut the fans off.
  4. - Make sure that the heater blower motor is turned off.
• If the Motorcraft® Engine Cooling System Cleaner VC-11/water mixture temperature in the tool kit bucket can not be maintained at or below 150°F (65°C):
  1. Make sure the upper radiator hose is properly positioned into the upper radiator hose locating bracket on the cooling fan shroud.
  2. Turn the blower motor to the highest setting, and the temperature to the hottest setting.
  3. If the engine is still overheating, turn the engine off, leave the key in the ON position and keep the tool kit pump circulating the VC-11/water mixture until the tool kit bucket temperature is reduced.
  4. Check for possible sources of air leaking into the cooling system.